I&T and Operating and Support Hazards Martin Nordby Chief Mechanical Engineer LSST Camera Safety Review August 18, 2015 R1

Topics Plans for capturing I&T and operating and support hazards LCA-15 Hazard List  O&SHA List I&T process flow development Operations Concept Document Maintenance planning Plans for addressing I&T and O&SH hazards through management processes Work planning Work control SLAC ES&H

LCA-15 Hazard List  O&SHA List As we have discussed, LCA-15 includes operating and support hazards Ultimately, these hazards will end up in a new Operating and Support Hazard Analysis List Our current Hazard List will be replaced by implemented designs and verification test results, demonstrating that hazards have been addressed The O&SHA will form the basis for capturing hazards involving personnel: Hazards associated with “generic” work associated with camera I&T: handling, hoisting and rigging, ESD and contamination control, … (this is what we currently have captured in the O&SHA hazards) Hazards associated with integration and test of partial assemblies or those in an incomplete state Hazards associated with troubleshooting and partial disassembly during maintenance and re-work These hazards are then addressed in the appropriate work planning and control (WP&C) documents We’ll walk through the process we are involved in now to identify these O&SHA hazards and then developing the necessary process controls

I&T process flow development I&T work processes are being developed using a detailed flow chart Basic work sequencing to integrate and test the camera (completed for CD-1 Review) Fixtures and test equipment needed for each step (completed for CD-2 Review) Detailed activity steps capture all aspects of the final design and define requirements for fixtures and test equipment (completed for CD-3 Review; in work) Work process steps and hazards associated with each activity Final traveler for each work process step, including hazards associated with the step and mitigations and controls to address the hazard Detail of I&T flow, showing verification tests in red

Operations Concept Document LCA-282, “Camera Operations Concept Document” captures plans for camera operations and maintenance We are using this to motivate decisions on operations plans for the camera, including: Operational break-down of camera components Camera internal state models Camera modes and transitions between modes Use cases for the camera in each mode For use cases with the camera in Maintenance Mode, one aspect of the use case and activity definition is an understanding of the hazards associated with carrying it out As the activities are further defined, we will develop procedures to implement them Camera Maintenance Mode Use Cases Access/Secure Camera Body Access Back Flange Maintain Mechanisms Access/Secure Utility Trunk Remove/Replace Mechanisms Leak Check Cryostat Inspect Components in Camera Body Service, Leak Check Vacuum Systems Access Front of Camera Replace System Electronics Swap Out Filter Component in Utility Trunk

Maintenance planning has been baked into the design Modularity allows for: Straightforward removal/replacement of components and assemblies Bench-top re-verification of assemblies prior to re-integration Minimizing impact on neighboring components and collateral damage Provisions for maintenance in the design Back flange bays: removable covers allow access for servicing and removing carousel components Housing portholes: provides access for replacement of carousel filter clamps Front flange notch: allows for quick removal of auto changer Shroud: removable panels provide access to L1-L2 strut feet, shutter, auto changer, and L3 Spare units Assemblies: Auto Changer, Shutter, RTMs Components: power supply boards, vacuum components, cabling Modular Components L1-L2 Assembly and L1 and L2 lens Auto Changer Carousel clamps and actuators Shutter Filters Raft Tower Modules Power Supply Boards Refrigeration system heat exchangers

Provisions for camera maintenance Removable panels in Utility Trunk provide access to power supply crates and vacuum components Notch in camera body allows for Auto Changer removal in situ Back flange bay covers removed SMRs are accessible for ground- or telescope-based survey and alignment, as needed All back flange mounting bolts are accessible for torque checking Portholes provide access to carousel clamps Shroud panels detach Camera access points for maintenance

Management processes for handling personnel and system hazards during I&T and maintenance Plans for addressing hazards through management processes The previous charts show how we have been/are/will be identifying O&SHA hazards Once identified, we have 3 broad sets of management processes to address mitigations and ensure that they are implemented Work planning Work control SLAC ES&H procedures

Work planning LCA-138 outlines our WP&C process; this boils down to two areas: Use of travelers Work activities are written down ahead of time, then reviewed and approved eTraveler system has been implemented to capture this entire process, including revision control on travelers Part of this process involves identifying O&S hazards, as well as risks to the hardware, environment, and health (industrial hygiene) MRRs and TRRs Manufacturing Readiness Reviews for subsystems and Test Readiness Reviews for the I&T effort will be used to provide a formal means to assess the totality of procedures, drawings, and other documentation that is in place

Work control During the I&T effort, work is controlled through a standard process implemented by the SLAC ES&H division and called out in LCA-138, PSAP This breaks down as follows: Training All personnel involved in camera I&T work will be registered users at SLAC Work scope and associated personnel hazards will be addressed, and the need for ES&H training assessed—training logs are managed by our ES&H Division Camera-specific training will address hazards related to equipment safety Authorization Work is authorized to be accomplished when approved travelers and trained personnel are identified to accomplish the work This recognizes the we are ready and capable to do the work Release of work Work is released to be done on a daily basis by the camera I&T floor manager Per SLAC ES&H processes, this is the only mechanism to start work This allows the work to be done

SLAC ES&H procedures Beyond the authorization and release process described, SLAC has pre-defined processes and requirements in place to authorize a number of other classes of work Examples: Work on high voltage (>50 V) electrical systems Hoisting and rigging Pressurized systems Work in elevated or confined space Seismic safety standards for equipment Oxygen deficiency …